Faculty of Engineering,
University of Ruhuna.
01
Introduction
Definition: A process for improving product design for easy and
02
Assembly Methods
Manual Assembly
Automatic Assembly
Robotic Assembly
-Workers manually
assemble the product or
components of a product
-Programmable
assembly machines
-Flexible
-Problem when
production increases
-Controlled by PLC or
computer
-Labor costs
03
Assembly Methods
Relative costs of different assembly methods by type and production
volume.
04
05
Boothroyd-dewhurst method
Relies on an existing design which is iteratively evaluated and
improved.
Steps:
1.
2.
3.
the analysis
4.
06
Part
ID#
i*
# of
Consecutive
identical
operations
2-digit
handling
code
Manual
handling
time/
part
2-digit
insertion
code
Manual
insertion
time/
part
Operati
on time
(bd+f)
Operation
cost
Essential
part?
Tm=
Cm=
Nm=
Nam
e
of
asse
mbly
Boothroyd-dewhurst method
Parts are evaluated as to whether it is really necessary (in the
assembly) by asking three questions:
Does the part move relative to another part?
Are the material properties of the part necessary?
Does the part need to be a separate entity for the sake of
assembly?
Boothroyd-dewhurst method
Lucas method
Boothroyd-Dewhurst method is based on timing each of the
handling and insertion motions
Lucas method is based on a "point scale" which gives a relative
measure of assembly difficulty
Functional Analysis
The components of the product are reviewed only for their function
and divided into two groups A and B
Group A - those that are essential to the product's function
Group B - those that are not essential to the product's function
Design efficiency = A / (A+B)x100%
Typically, a design efficiency of 60% is targeted for initial designs.
Feeding/Handling Analysis
Both the part handling and insertion times are examined
Feeding Ratio
B. Handling difficulties
All that apply
1.5
1
1.5
Delicate
0.4
Flexible
0.6
Sticky
0.5
Tangible
0.8
Severely nest
0.7
Sharp/Abrasive
0.3
Untouchable
0.5
0.2
3
No handling difficulties
C. Orientation of Part
One of the following:
0.1
0.2
0.4
0.5
Fitting Analysis
Need to know the proposed assembly sequence
Relative difficulty in assembling the complete product is
determined.
Whether the component needs to holding in a fixture
The assembly direction
Alignment problems
Restricted vision
Required insertion force
Fitting ratio =Total fitting index/No. of essential components
B. Process Direction
One of the following
Self-holding orientation
1.0
0.1
Requires holding
Plus 1 of the following
2.0
1.6
1.3
Screwing
4.0
Riveting
4.0
Bending
4.0
D. Access and/or
Vision
One of the following
Direct
Restricted
C. Insertion
One of the following
Single
0
1.5
E. Alignment
One of the following
Multiple insertions
0.7
Easy to align
1.2
Difficult to align
0
0.7
F. Insertion Force
One of the following
No resistance to insertion
Resistance to insertion
0
0.6
Manufacturing Analysis
Find the cost of manufacturing each component